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Poultry

At Hydroflux Industrial, our engineers are fully conversant with the internal production processes of poultry slaughterhouses and further processing plants and as such, we understand the sources of the wastewater. This enables us to design complete treatment plants that work efficiently, economically and consistently under all conditions.

We have a comprehensive range of primary treatment equipment such as screens and dissolved air flotation system plus advanced biological processes including sequential bioreactors, membrane bioreactors and moving bed bioreactors.

Wastewater from poultry slaughterhouses is heavily loaded with solids, fat, feathers, blood, manure, and a variety of organic compounds originating from proteins. The actual composition of the wastewater from each facility depends on the actual production methods employed, but from the point of view of a wastewater treatment designer, there are adequate similarities to enable designs to be made for Greenfield sites.

The main sources of water contamination are from the holding sheds, crate and truck washing, slaughtering, evisceration, scald tanks, chillers, rendering, trimming, and general cleaning.

Poultry slaughterhouse wastewater contains a variety of biodegradable organic compounds, mainly consisting of particulate and dissolved fats and proteins. In comparison to many other food processing wastewater, poultry slaughterhouse wastewater is generally considered to be of a reasonably high strength in terms of biochemical oxygen demand (BOD), chemical oxygen demand (COD), suspended solids (SS) and particularly high in nitrogen and phosphorus. The pH is generally around neutral.

The two most significant streams to consider are dumping of the chillers being high instantaneous volume chlorine laden wastewater and the scald tanks. Blood and meat proteins are the most significant sources of nitrogen in the wastewater and rapidly give rise to ammonical nitrogen as breakdown occurs. Additionally blood (which has a COD of about 400,000 mg/L), if not properly controlled will add considerably to the organic load in the wastewater.

Wastewater from FPP facilities can contain very high concentrations of solids, grease and COD

Further poultry processing

Wastewater generated from further poultry processing (FPP) is very different to wastewater generated from the slaughtering process. Due to the varied nature of further processing this wastewater can contain flours, starch, various oils, high quantities of fats from cooking processes and other ingredients that are added.

These substances significantly increase the solids and grease loads leaving to very high BOD and COD sometimes well in excess of 10,000mg/L. Other issues to overcome are very sporadic flows and very high instantaneous loads experienced at the start of the cleaning porcess.

Hydroflux has much experience in the design and construction of wastewater from FPP plants and we know the questions to ask to obtain the information necessary to ensure that your plant works consistantly, not just most of the time.

Hydroflux DAF system suitable of treating 1.2ML/day as a complete preassembled unit

Primary Treatment

Primary treatment of wastewater from poultry slaughterhouses is a generally considered to be good practice as the bulk of the solids and grease can be quite easily and inexpensively removed which significantly reduces the load on any secondary plant.

Primary treatment methods include one or all of the following:

Fat traps

Screens (please click here for details on the various types of screens available)

DAF units are still extensively used within the poultry processing industry. The effectiveness of a DAF system depends on a number of factors including; whether or not chemicals are dosed and its position within the overall process.

We can conduct jar testing to provide accurate predictions of performance

The efficiency of the process for fat removal is reduced if the temperature of the water is too hot. The increase in fat recovery from reducing the wastewater temperature from 40 to 30 degrees C can be up to 50%, so heat exchangers can play a vital part in terms of performance or recovery of fat.

Without chemical treatment, a DAF system will remove 20–30% of the COD/BOD, 30–60% of the SS, and 60–90% of the oil and grease. The percentage reduction increases with an increased load entering the plant. It should also be noted that sedimentation will occur without chemical dosing and should be addressed.

Chemical treatment can significantly improve the performance of a DAF system. Historically ferric chloride or Alum is used to precipitate proteins and polymers used to aid coagulation, however with advances in polymer design, a high dose of polymer can be almost as effective at a considerably lower cost with a further benefit of generating less sludge. BOD reductions of 80% or more can be achieved with a suitable chemical program with over 95% reduction in solids and grease.

Another important aspect to consider is the speed in which the wastewater is treated in the DAF. When wastewater is treated quickly, less ammonical nitrogen is formed and thus the DAF system can remove quite significant amounts of nitrogen. Up to 60% is possible in some cases.

Poultry primary treatment process diagram with DAF

Please click on the image for a typical primary treatment process diagram or call on 1300 417 697 to speak to one of our poultry experts.

Using biological treatment, can treat wastewater to achieve very low levels of organics and nutrients. Aerobic treatment can allow wastewater to discharged to the environment or with tertiary treatment allow for reuse.

Aerobic biological treatment for the treatment of biodegradable wastes has been used for many years and can be designed to reduce influent BOD by 95% or more. As wastewater form meat processing plants is highly biodegradable, such systems are ideal and quite common practise.

In determining what the most suitable biological process is, a number of factors need to be taken into account. These include; the performance requirements, the land area available, energy costs and efficiency, and waste biomass production.

Of particular note in terms of performance requirements are the increasingly stringent nutrient limits being imposed in all states and territories of Australia. Removing organic material (or BOD) is relatively simple and energy efficient whereas nitrification and denitrification processes require considerably more power.

The type and size of biological system also depends on the upstream treatment methods. Typically due to the cost of operating a biological plant, upstream treatment should be optimised for maximum economic performance.

As there are so many variations to biological plant design, we invite you to have a look at our web pages on this topic here and contact us if you require any specific information.

Membrane Bio Reactors
Hydroflux Industrial MBR’s are becoming increasingly popular for industrial wastewater treatment due to its small footprint, reliably, decreasing life-cycle costs and the ability for wastewater reuse.(more info).

Complete Systems
Hydroflux Industrial do not only specialise in the design of high quality biological processes but will also design and construct entire turnkey wastewater treatment plants.(more info).

When Hydroflux Industrial provides complete solutions, we can either undertake a contract on a turnkey basis or work together with building services engineers and other construction professionals such as architects, structural engineers and quantity surveyors to ensure that the project is delivered smoothly, without interruption and on time.

BUILD OPERATE TRANSFER (BOT) FINANCING

The Hydroflux Group is able to offer a Build Operate & Transfer (BOT) option for water and wastewater assets in Australia and New Zealand. This innovative partnership arrangement strengthens existing strong bonds between Hydroflux and their customers for the long term.

Hydroflux, represented by a special purpose vehicle dedicated to the project, supplies the design, construction, financing, and operation of the water or wastewater plant. The plant is transferred to the client at the end of the contract, which is generally around 10 years.

Hydroflux also purchase existing water and wastewater plants on a similar basis, which releases cash to our clients for either returning or distributing to investors or for funding other investments in their core business.

The multidisciplinary structure of the Hydroflux group including design, construction, equipment supply and operation makes Hydroflux the ideal BOT water and wastewater partner.

Please contact Hydroflux if would like to explore the option of either acquiring a new water or wastewater facility without capital outlay or would like to free up cash by selling your existing water or wastewater assets.